Seat belt buckle

ABSTRACT

A seat belt buckle for use in vehicles is provided. The seat belt buckle includes a base and a cover removably fixed to the base. The base includes a bottom surface, a pair of sidewalls, and a plate fixed to the bottom surface and extending laterally therefrom. The plate includes an opening having a width of or greater than about 2 inches. The seat belt (webbing) can be fed directly through the opening without the need to fold the webbing inward from its edges. The webbing can also be easily manipulated around and through the opening to avoid snagging or clogging the webbing in the buckle.

TECHNICAL FIELD

The present invention relates to a seat belt buckle for use with webbing (seat belt) in a vehicle, such as a passenger automobile, and in particular to a seat belt buckle having an opening configured to receive unfolded webbing.

BACKGROUND

Conventional seat belt systems include a tongue plate configured for insertion into a slot in the main body of a buckle. Webbing (seat belts) attached to a vehicle seat or to the vehicle cabin passes through respective openings in the ends of the tongue plate and the buckle. When the tongue plate has been inserted into the slot in the main body of the buckle and latched in a locking member housed therein, the respective webbings operate to secure a passenger against the seat and prevent the passenger from being seriously injured or ejected from the vehicle in the event of an accident.

Because space within the vehicle's cabin and around the vehicle seat is limited, small buckles have been favored. Traditionally, these small buckles house an opening for webbing that is narrow, often in the range of only three-quarters to one-inch wide. To pass through the opening, the webbing for the seat belt (typically two inches wide) must be folded multiple times over, often in very specific configurations. The folded webbing is typically clunky, prone to snagging or clogging in the opening, difficult for a passenger to manually manipulate when adjusting the seat belt, and visually unappealing. Thus, while the small buckles have enabled manufacturers to maximize space in or around the vehicle seat, manufacturers have been required to invest valuable resources and human capital simply into folding webbing. The folding step also adds time and cost to the manufacturing process.

Accordingly, it is desirable to provide a buckle with an opening that does not require the webbing to be folded to pass therethrough. Ideally, the webbing can simply be fed through the buckle opening, looped around and affixed to itself. It is desirable to provide an opening that will allow passengers to easily navigate the buckle around the webbing when adjusting the seat belt system, avoid snagging or clogging the webbing in the buckle, and provide for an improved visual appearance when the webbing is assembled with the buckle, as well.

SUMMARY

In accordance with one aspect of the present disclosure, a base for a seat belt buckle is provided. The base includes a bottom surface, a pair of side walls, and a plate fixed to the bottom surface and extending laterally therefrom. The plate includes an opening having a width between about 2 inches to about 2.5 inches.

In accordance with another aspect of the present disclosure, a seat belt buckle is provided. The seat belt buckle includes a base and a cover removably fixed to the base. The base includes a bottom surface, a pair of sidewalls, and a plate fixed to the bottom surface and extending laterally therefrom. The plate includes an opening having a width between about 2 inches to about 2.5 inches.

BRIEF DESCRIPTION OF FIGURES

FIG. 1 is a perspective view of an embodiment of a seat belt buckle assembled from an cover and a base.

FIG. 2 illustrates an exploded perspective view of a disassembled seat belt buckle embodied in FIG. 1.

FIG. 3 illustrates an exploded perspective view of the base of the seat belt buckle embodied in FIG. 1.

FIG. 4 illustrates a side perspective view of the base of the seat belt buckle embodied in FIG. 1.

FIG. 5 shows a plan view of the base of the seat belt buckle embodied in FIG. 1.

FIG. 6 illustrates a front view of another embodiment of a base of a seat belt buckle.

FIG. 7 illustrates a side view of an assembled seat belt buckle embodied in FIG. 1 that has had webbing fed through an opening in a plate portion thereof.

DESCRIPTION

FIG. 1 is a perspective view showing an overall structure of a seat belt buckle 1 according to an embodiment of the present invention. The seat belt buckle 1 includes a base 2 that has a substantially U-shaped cross-sectional configuration and a plate 13 fixed thereto and extending therefrom, and a cover 3 removably fixed to the base 2 having a locking member and a push button 4. As illustrated in FIG. 1, the plate 13 is not housed within (enclosed) by the cover 3 when fixed to the base 2. FIG. 2 is an exploded perspective view of the disassembled buckle 1 with the cover 3 removed from the base 2 and the plate portion 13 extending from the base 2.

FIG. 3 is an exploded perspective view of the base 2 of the seat belt buckle 1. FIGS. 4 and 5 are a side perspective view and a plan view, respectively, of the base 2 of the seat belt buckle 1. As shown in FIGS. 3-5, the base 2 includes a back end 5, a front end 6, a bottom surface 2 a that is substantially a flat plate, and a pair of side walls 2 b and 2 c bounding the bottom surface 2 a on either side. The materials used for the base 2 are not particularly limited and may include, for example, a metal, a plastic, or a combination thereof. The side walls 2 b and 2 c substantially form right angles with the bottom surface 2 a and may be integrally formed therewith. Alternatively, the side walls 2 b and 2 c and the bottom surface 2 a may be formed separately and joined together, such as by metal or plastic welding.

A slot 7 is located at a front end 6 of the base 2. The slot 7 is substantially defined by tab portions 8 a, 8 b extending from side walls 2 b, 2 c, the bottom surface 2 a, and side walls 2 b, 2 c of the base 2. The tab portions 8 a, 8 b may be formed by cutting each of the side walls 2 b, 2 c in a horizontal direction at the front end 6 of the base 2 and bending the cut portions towards the interior of the base 2 at substantially right angles to the side walls. The slot 7 has a predetermined length and width that are configured to accommodate the dimensions of a complementary tongue plate (not shown). When the cover 3 is assembled onto the base 2 and a tongue plate is inserted through the slot 7, the tongue plate will removably engages with a locking mechanism (not shown) in the cover 3.

The base 2 includes a pair of slide grooves 9 a, 9 b formed in the side walls 2 b, 2 c. The slide grooves 9 a, 9 b extend longitudinally with respect to the base 2. So formed, the slide grooves 9 a, 9 b formed in respective side walls 2 b, 2 c face each other. The size and shape of the slide grooves 8 b, 8 c are not particularly limited. The slide grooves 9 a, 9 b are configured to mate with respective slide grooves in the cover 3 so as to removably fix the cover 3 to the base 2.

The base 2 also contains other features configured to mate with respective features in the cover 3 to secure the cover 3 to the base 2. For example, a guide hole 10 is formed within (i.e., passes through) the bottom surface 2 a of the base 2. As illustrated in FIG. 5, the guide hole 10 is substantially rectangular. However, the shape, size and dimensions of the guide hole 10 are not limited and the guide hole 10 may be formed from a combination of shapes. This combination is illustrated in FIG. 6 where the guide hole 10 has a substantially elliptical top portion and a substantially rectangular bottom portion. Typically, the guide hole 10 is configured to receive (mate with) the locking mechanism housed in the cover 3.

Additionally, a protrusion 10 a may be formed on the bottom surface 2 a. When present, the protrusion 10 a is formed at a position along the perimeter of the guide hole 10 and projects perpendicularly from the bottom surface 2 a of the base 2. The protrusion 10 a is also configured to receive (mate with) with the locking mechanism in the cover 3. The base 2 may also contain one or more additional protrusions 11 configured to interact with respective recesses or protrusions on the locking mechanism or the cover 3.

The base 2 also contains a pair of curved grooves 12 a, 12 b formed in respective portions of the side walls 2 b, 2 c. Preferably, the curved grooves 12 a, 12 b are positioned on the side walls 2 b, 2 c near the back end 5 of the base 2. The curved grooves 12 a, 12 b have a substantially arcuate configuration when seen from the side in FIGS. 3-4. A pair of tabs (not shown) in the cover 3 are configured to mate with the curved grooves 12 a, 12 b to further secure the cover 3 to the base 2 during assembly. Thus, the combined interaction between each of features 10, 10 a, 11, 12 a, 12 b in the base 2 with their corresponding features in the cover 3 serve to removably fix the cover 3 to the base 2.

A plate 13 extends from the back end 5 of the base 2. The plate 13 extends from, and preferably is co-planar with, the bottom surface 2 a of the base 2 and is not bounded by side walls 2 b, 2 c. The plate 13 may be formed of the same materials as the base 2, or may be formed of a different material. In one embodiment, both the plate 13 and the base 2 may be made of metal, or both may be made of plastic. Alternatively, one of the plate 13 or the base 2 may be made of plastic, while the other may be made of metal. The plate 13 may be integrally formed with the base 2. Alternatively, the plate 13 and the base 2 may be separately formed and attached thereto by, for example, by snap-fitting protrusions in the plate 13 with recesses in the bottom surface 2 a of the base, or by welding the plate 13 and the bottom surface 2 a of the base 2 together.

The dimensions and shape of the plate 13 are not particularly limited, except that they must be sufficient to accommodate the opening 14 as hereafter discussed. As illustrated in FIGS. 2-5, for example, the width of the plate 13 may be greater than the width of the bottom surface 2 a of the base 2, such that the width of plate 13 extends beyond the width of the bottom surface 2 a of the base 2. Alternatively, the plate 13 and the bottom surface 2 a of the base 2 may have the same width, or the plate portion 13 may have a smaller width than the bottom surface 2 a. In another embodiment, as illustrated in FIGS. 1-5, the plate 13 may be substantially rectangular. Alternatively, as illustrated in FIG. 6, the plate 13 may be substantially elliptical.

The plate 13 has an opening 14 therethrough that is configured to receive webbing 15 (shown in FIG. 7). The opening 14 may be integrally formed within the plate portion 13 during the manufacturing process, such as by using a mold, or the opening 14 may be etched, drilled, or otherwise cut into the plate 13. As illustrated in FIG. 5, the opening 14 has a width (W) sufficient to accommodate the full width of the web forming the seatbelt (i.e. without folding out inward from its outer edges), and preferably is at least 1.5 inches wide, most preferably about or at least 2 inches wide. The opening also has a length (L) of at least about 0.1 inch, optionally at least about 0.5 inch and up to about 1 inch. A range of about 0.25 inch to about 0.4 inch is preferred. In the disclosed embodiments, it is not necessary to fold the webbing to fit the webbing through the opening 14 as is conventionally done in the art. Rather, the webbing 15 can be directly fed through the opening 14 across its full width without folding width-wise. In addition, when the width (W) and/or length (L) of the opening are so dimensioned, the webbing 15 may be easily manipulated around the opening 14 and the plate 13 to adjust the buckle to fit around the passenger, and to avoid snagging or clogging the webbing in the opening 14.

As illustrated in FIG. 6, the opening 14 may be substantially surrounded by one or more projections 16 disposed on at least one surface of the plate 13. The shape and dimensions of the projections 16 are not particularly limited. In the illustrated embodiment, the projection 16 is ellipse-shaped to conform to the ellipse-shaped plate 13. However, the one or more projections 16 may be in the form of one or a series of lines, dots, semi-circles, or any other shape. The one or more projections 16 shields the opening 14 from debris, dirt or any other obstruction in or around the buckle 1 that may clog the opening 14 and interfere with movement of the webbing therethrough. The one or more projections 16 also provide a textured point of contact for a passenger to grasp when searching for a buckle 1 that has fallen between seats or off the seat into the vehicle cabin, or when adjusting the webbing.

Referring back to FIGS. 1 and 2, the cover 3 has a locking member (not shown) and a push button 4. The materials and dimensions of the cover 3 are not particularly limited. When the cover 3 is assembled onto the base 2 as described above, and the tongue plate is inserted through the slot 7, the tongue plate removably engages with the locking mechanism in the cover 3. When pressed, the push button 4 causes the locking mechanism to release the tongue plate so that the tongue plate can be retracted through the slot 7. The push button 4 may be colored, dimensioned and/or textured differently than the cover 3 so that the push button 4 may be quickly and easily recognized by a passenger. For example, the cover 3 may be black and the push button 4 may be red. In another example, the top surface of the push button 4 may be positioned above or below the top surface of the cover 3. In another example, the push button 4 may have the letters “PUSH” etched therein.

The following will describe how the webbing 15 may be inserted through the opening 14 in the plate portion 13. Conventionally, webbing 15 is made of a woven fabric, such as nylon, polyester, or a combination thereof, though the webbing 15 for use with the buckle 1 is not limited to these materials. As illustrated in FIG. 7, a free end 15 a of the webbing 15 is threaded through the opening 14. The free end 15 a of webbing 15 is then looped back around the plate portion 13 in the direction from which it was initially fed and is folded back onto itself along its longitudinal axis, and attached to another portion of the webbing 15. FIG. 7 shows a free end 15 a of the webbing 15 that was threaded through the top of the opening 14 and attached to a bottom surface of the webbing 15. However, the free end 15 a of the webbing 15 may alternatively be fed through the bottom of the opening 14 and attached to a top surface of the webbing 15. The free end 15 a of the webbing 15 may be attached to the top or the bottom surface of the webbing 15 by any means known in the art, such as by stitching, by applying a fabric adhesive to one or more surfaces of the webbing, or a combination thereof. In some embodiments, the free end 15 a of the webbing 15 may be attached to the top or the bottom surface of the webbing 15 with a sewn design to enhance its visual appearance.

Although the invention has been described with respect to select embodiments, it shall be understood that the scope of the invention is not to be thereby limited, and that it instead shall embrace all modifications and alterations thereof coming within the spirit and scope of the appended claims. 

1. A base for a seat belt buckle, the base comprising: a bottom surface; a pair of side walls; and a plate fixed to the bottom surface and extending therefrom, wherein the plate comprises an opening having a width about or at least 2 inches.
 2. The base of claim 1, wherein the opening has a length between about 0.25 inch to about 0.4 inch.
 3. The base of claim 1, wherein the opening is configured to receive an unfolded free end of a webbing of a seatbelt.
 4. The base of claim 1, further comprising a full-width seatbelt web threaded through said opening.
 5. The base of claim 1 further comprising a slot opposite to said plate, wherein said slot is substantially defined by tab portions of the side walls, the side walls, and the bottom surface.
 6. The base of claim 1, wherein each side wall comprises a slide groove.
 7. The base of claim 8, wherein the bottom surface comprises a guide hole and a protrusion projecting perpendicularly from the bottom surface at a position along the perimeter of the guide hole.
 8. A seat belt buckle comprising a slot adapted to accommodate a tongue plate therein for locking the tongue plate into the buckle to fasten the seat belt, and an exposed plate opposite to said slot and having therein an opening whose width is about or at least 2 inches. 